CAREFREE ONE-TOUCH WINDOW AWNING With Stop Installation and Operations Manual T0002 052504-001 Printed in USA November, 2003
TABLE OF CONTENTS Introduction... 1 Product Overview... 1 Safety Information... 1 Safety Notes:... 1 Installation... 2 Tools and Components Checklist... 2 Tools and Supplies... 2 Components... 2 Before Installing the Awning... 3 Installing the Awning Rail (For New Installations)... 3 Assembling the Awning... 4 Mounting the Awning... 5 Wiring... 6 Installing the Electrical Wire... 6 Installing the Control Switch... 6 Final Assembly... 8 Securing the Fabric... 8 Setting the Awning Extension Stop... 9 To Set the Awning Extension (initial installation):... 9 To Change the Awning Extension:... 9 Operation... 10 Extending the Awning... 10 Retracting the Awning... 10 Maintenance... 10 Fabric Maintenance... 10 Hardware Maintenance... 10 Motor Maintenance... 10 Troubleshooting... 11 Warranty Policy... 12 Carefree of Colorado 2145 W. 6 th Avenue Broomfield, CO 80020 a Scott Fetzer company 303-469-3324 www.carefreeofcolorado.com 052504-001 Printed in USA November, 2003
INTRODUCTION PRODUCT OVERVIEW The new is designed to install as a new awning or as replacement awning arms for existing Carefree window awnings up to a maximum awning width of 13 feet. For new installations, the One-Touch Awning Rollbar kit must be ordered separately from the arms and includes the rollbar assembly, awning rail and attaching hardware. One-Touch Awning Specifications: The awning operates on 12VDC (range 10VDC to 14VDC). As a replacement installation, the new arms come with cover plates to allow installers to use existing mounting hole locations. For new installations: Window awnings are available in 6 inch increments from 3 feet to 7 feet and in 1 foot increments from 7 feet to 13 feet. Measure the width of the window, including the frame. Add 4 1/2 for mounting brackets. This is the minimum required width of the awning. Use the awning length one increment above the minimum required width. Example: Window Frame Window and Frame measures 35 adding 4 1/2 equals 39 1/2. The correct awning width is, 42. 2 1/4" 2 1/4" T0003 Figure 1. Minimum Measurement. The Sunbrella fabric is available in 120 colors plus custom designed graphics. The optional Alumaguard weather guard wrap system is available to protect the awning from inclement weather conditions. SAFETY INFORMATION WARNING A WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY AND/OR MAJOR PROPERTY DAMAGE. CAUTION A CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT MAY CAUSE MINOR TO MODERATE PERSONAL INJURY AND/OR PROPERTY DAMAGE. IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES. NOTE: A note indicates further information about a product, part, or step. Tip: A tip provides helpful suggestions. Safety Notes: Always disconnect battery or power source before working on or around the electrical system. Always wear appropriate safety equipment (i.e. goggles). Always use appropriate lifting devices and/or helpers when lifting or holding heavy objects. 1 052504-001
INSTALLATION TOOLS AND COMPONENTS CHECKLIST Use the following checklist to verify that you have all the tools and parts necessary to install and operate the product. Immediately contact the supplier if any parts are missing or damaged. You will not be able to install/operate the product. Tools and Supplies Description Description Description Square Wire Cutter/Crimper Silicone Spray Lubricant #2 Phillips Screwdriver Tape Measure Silicone Sealant Drill Motor Metal File Caulking Gun Drill Bits (1/8, 5/32, 3/16", 7/16 ) Step Ladder 2 1/4 Hole Saw Nut Drivers (5/16, 7/16 ) Marking Pen Components Roller Assembly Kit (Ordered Seperately) Description LH Arm Assy (non-motorized) RH Arm Assy (motorized) QTY 1 1 Stop Cap 1 Grommet 1 Description Screw, #10 x 3/4 QTY A/R Screw, #6 x 3/8 2 Awning Rail 1 Rollbar Assembly 1 Electrical Kit Description QTY Switch, DPDT 1 Momentary Contact Switch Plate 1 Spade Connector 4 Female Screw, #6 x 1/2 4 Hardware Packs (A = Replacement Installation, B = New Installation) QTY QTY Description A B Description A B Cover Plate 2 - Rivet, Pop, 3/16 4 4 Bumpers (set of 2) 1 1 Figure 2. Product Components. Rivet, Moly, 3/16 12 Screw, Truss, #6 x 1/2 1 1 Screw, #10 x 3/4 12 4 2 052504-001 4 T0004
BEFORE INSTALLING THE AWNING 1. Park the vehicle on a flat surface and level the unit. 2. For existing installations, remove the existing arms from the vehicle. Use the information furnished with the original awning. NOTE: Do not remove the awning rollbar from the vehicle. The rollbar can hang from the awning rail. 3. Thoroughly clean the vehicle walls where the new arms are to be attached. Remove any old caulking or sealant. 4. Check where the awning arms will be installed. The arms fit closely to the side of the vehicle and must not cover or interfere with exhaust vents, lights etc. For new installations, if there is an awning rail installed, check that the awning rail runs the full length of the awning. If no rail is installed or it does not cover the required length of the awning, follow the instructions under Installing the Awning Rail. For fabric awnings, a standard awning rail with a 3/8 inside diameter track is required. For Alumaguard installations, it is necessary to use the Carefree awning rail specifically made for these installations. NOTE: For new installations, it is necessary to order the rollbar assembly kit. The appropriate awning rail and attaching hardware is included. INSTALLING THE AWNING RAIL (FOR NEW INSTALLATIONS) 1. Determine the optimum positioning of the awning so that the arms will not interfere with the window frame or light fixtures. The recommended height is 3 above the window frame. 2. The awning rail must be level. 3. After determining mounting position, mark the position with a chalk line. 4. Seal the back of the rail with silicone sealant or putty tape. 5. Align the awning rail onto the wall and secure with the supplied #10 x 3/4 screws. Use all the attach holes in the rail. CAUTION MAKE SURE THE SCREWS ARE SECURELY MOUNTED TO THE STRUCTUAL FRAME OF THE VEHICLE. 6. Use a screwdriver to spread open one end of the awning rail track on the installation side. 7. File any sharp edges or burrs from the end of the mounting bracket. This will help protect the awning fabric from damage during installation. 8. Spray inside the awning rail track with silicone lubricant. Spread open the end of the awning rail Figure 3. Spreading Open the Awning Rail. T0012 3 052504-001
ASSEMBLING THE AWNING NOTES: For existing installations, allow the fabric to unroll. Support the rollbar on an appropriate surface or work table. For installations that do not use the cover plate, start at step 3. 1. (Refer to Figure 4) On the motorized arm, Insert the cover plate into the support bracket through the hole in the back of the bracket as shown in figure. The plate will sit loosely inside the bracket. 2. Repeat for the other arm. Support Bracket Cover Plate Figure 4. Installing the Cover Plate. (Refer to Figure 5) 3. On the motorized arm, align the spider with the inside of the roller assembly. Begin inserting the roller assembly into the roller end cap. 4. Rotate the end cap so that the ridge inside the cap aligns with the slot in the roller and finish inserting the roller fully into the end cap. 5. Secure the end cap to the roller assembly using two (2) 3/16 blind rivets. The rivets should be on opposite sides (180 apart). 6. Fully insert the roller assembly into the roller end cap on the non-motorized arm and attach using (2) 3/16 blind rivets. The rivets should be on opposite sides (180 apart). Roller Assembly Non-Motorized Arm Assembly (LH) 3/16" Pop Rivet Roller End Cap 90 Figure 5. Assembling the Awning. Polyrod Spider Motorized Arm Assembly (RH) T0005 Toward Wall T0006 4 052504-001
MOUNTING THE AWNING NOTES: During these steps, a second person is required to hold and steady the awning during installation. The arms may be attached to the vehicle wall using 3/16 moly pop rivets or the #10 hex head screws. Rivets require a 3/16 hole, the screws require a 1/8 pilot hole. (For new installations) 1. Unroll the canopy one wrap. 2. Carefully slide the polyrod (the plastic rod on the edge of the fabric) into the awning rail. Gently pull the fabric into the rail until the awning is centered over the window. NOTE: While the fabric is fairly robust, care must be taken not to snag it on the rail. (For all installations 3. Align the centerline of the rollbar with the centerline of the awning rail track. 4. Ensure that the motorized arm is perpendicular to the roller assembly and mark the location. 5. Remove the protective film from the support bracket and firmly press the arm assembly against the wall in the position marked in step 5. (refer to Figure 6) 6. Attach the arms to the vehicle wall through the bottom mounting hole of the support bracket. 7. For installations using the cover plate, attach the plate to the vehicle wall in the four holes in the plate. These should match up to the existing holes from the previous installation. Support Bracket Upper Mounting Hole Lower Mounting Hole New Installation Figure 7. Arm Mounting Holes. 8. Ensure that the non motorized arm is perpendicular to the roller assembly. 9. Repeat steps 5 through 7 for the non-motorized arm assembly. 10. Using a non-permanent marker or tape, mark the location where the awning rail contacts the arm heads. 11. Remove the tie wraps and open the awning to expose the upper mounting holes in the bracket support, and secure the arms. NOTE: To open or close the awning, momentarily connect the motor wires to a 9-18VDC drill battery or car battery. If the motor runs in the reverse direction, reverse the leads. 12. While the awning is extended, clean the surface then attach the rubber bumpers (one per side) on the arm heads at the locations marked in step 11. 13. Retract the awning. Replacement Installation Support Bracket Upper Mounting Hole Cover Plate Lower Mounting Hole T0007 Figure 6. Bumper Installed. Bumper Awning Rail T0008 5 052504-001
WIRING INSTALLING THE ELECTRICAL WIRE 1. Mark and drill a 7/16 hole through the exterior wall of the vehicle within the area shown. CAUTION MEASURE AND MARK CAFEFULLY. MAKE A NOTE OF THE LOCATION OF ANY INTERIOR FRAMING, CABINETS, ELECTRICAL COMPONENTS OR OTHER STRUCTURE THAT COULD BE DAMAGED OR INTERFERE WITH THE HOLE LOCATION. ADJUST THE LOCATION WITHIN THE DESIGNATED AREA AS REQUIRED. 2. Slide the grommet over the motor wires. 3. Insert the wires in the hole drilled in step 1. 4. Coat the inside flange of the grommet with a quality silicone sealant then firmly seat the grommet into the hole. 5. Adjust the wires through the grommet to allow a small downward loop between the arm assembly and the grommet. This is to prevent moisture from following the wire into the vehicle. 6. Seal the wires and grommet using a silicone sealant. INSTALLING THE CONTROL SWITCH 1. Determine the location of the switch. There is approximately 40 of wire from the point of entry. Location should provide the operator a view of the awning during operation. The switch requires a 2 3/4 x 2 3/4 area on the mounting surface and a minimum clearance depth of 2 3/4 from the mounting surface. Locking Tabs Covered Terminals on Bottom Figure 9. Switch Assembly. 1" (min) 2 3/4" (typ.) 3" (max) 2. Using a 2 1/4 hole saw, drill a hole through the mounting surface. 3. Route the awning wires through the hole and terminate with spade connectors. 4" (min) Drill Area for Wires 7/16" Hole 6" (max) Figure 8. Drill Location. 2 3/4" (min.) E0010 T0009 6 052504-001
CAUTION ALWAYS DISCONNECT THE VEHICLE BATTERY AND ELECTRICAL SOURCES BEFORE WORKING WITH THE ELECTRICAL WIRING. 4. Run a 14 gauge wire (never use less than 16 gauge) from the power distribution panel (auxiliary battery circuit) or equivalent. The circuit should be protected by a 15 amp fuse. 5. Run a wire to chassis ground. Suitable ground would be the vehicle chassis or conductive structure connected to the chassis. 6. Route the two new wires through the hole and terminate with spade connectors. 7. Push the switch into the face plate until the tabs on the switch click into place behind the face plate. Ensure that the switch and face plate are oriented as shown. (Refer to Figures 9 & 10) 8. Attach the four wires to the switch as shown. (Refer to Figure 10) 9. Push the wires and switch into the mounting hole and secure the plate using four (4) #6 x 1/2 screws. 10. Restore vehicle power and test operation. Wall Carefree of Colorado 40 Black Front View of Switch Panel Figure 10. Switch Wiring. Ground 6 5B 4 3 2B +12VDC CAUTION 1 Red Rear View of Switch Panel TERMINALS 1 AND 4 ARE CAPPED WITH FULLY INSULATED CONNECTORS. THESE TERMINALS MUST REMAIN CAPPED AT ALL TIMES. T0011 7 052504-001
FINAL ASSEMBLY SECURING THE FABRIC 1. To verify that the fabric is square on the rollbar, roll the awning in and out several times. 2. Secure the canopy fabric or Alumaguard using one, #6 x 3/8" hex head screw at both sides of the awning. See Figure 11. For vinyl (non Alumaguard) awnings, place screw through awning rail, polyrod and canopy approximately 1 in from the end of the fabric. See Figure 11A. For Alumaguard awnings, place screw on the outer edge of the Alumaguard (not through the Alumaguard). See Figure 11B. NOTE: The securing screws are included with the rollbar kit Awning Rail Awning Rail Fabric 1" Alumaguard Polyrod #6 x 3/8 Screw #6 x 3/8 Screw E0014 Figure 11. Securing the Fabric. 8 052504-001
SETTING THE AWNING EXTENSION STOP The extension stop for the One-Touch Awning can be set to stop before reaching the full extension of the canopy. Access Hole Adjustment Bolt Loosen Tighten Figure 12. Awning Stop Adjustment Bolt. To Set the Awning Extension (initial installation): 1. Extend the awning to the desired position. Stop Cap #6 x 1/2 Screw Truss Head NOTE: The maximum extension for the awning is when the valance hangs straight down from the roller. Failure to stop at this point can cause the awning to reverse roll onto the roller causing the awning to not operate correctly. 2. Hand tighten the adjustment bolt with a 7/16 hex socket until it bottoms out. Do not torque the bolt. 3. Install the stop cap and #6 x 1/2 screw. Hand tighten the screw. Over tightening can cause the threads to strip out in the plastic housing. To Change the Awning Extension: 1. With the awning retracted, remove the screw and stop cap from the motor housing. The stop cap is a tight fit, to aid in removal, insert a small screwdriver or pin into the access hole on the opposite side of the stop cap. Lightly tap until the plug is pushed out. Lightly tap the adjustment bolt head in before continuing. 2. Extend the awning to the desired position. 3. Hand tighten the adjustment bolt with a 7/16 hex socket until it bottoms out. Do not torque the bolt. 4. Install the stop cap and screw removed in step 1. Hand tighten the screw. Over tightening can cause the threads to strip out in the plastic housing. T0010 9 052504-001
OPERATION EXTENDING THE AWNING To extend the awning, press and hold the switch in the EXTEND position until the awning is in the desired position then release the switch. RETRACTING THE AWNING To retract th awning, press and hold the switch in the RETRACT position until the awning is in the desired position then release the switch. MAINTENANCE FABRIC MAINTENANCE CAUTION DO NOT USE OIL BASED CLEANERS OR ANY CAUSTIC, GRANULATED, OR ABRASIVE TYPE CLEANERS ON THE CAREFREE PRODUCT. One of the best ways to keep the fabric looking good and to delay the need for deep or vigorous cleanings is to hose fabrics off on a monthly basis with clear water. This will help prevent dirt from becoming deeply imbedded in the fabric. In most environments, a thorough cleaning will be needed every two to three years. When it's time for a thorough cleaning, the fabric can be cleaned while still on an awning frame or, size permitting, it can be removed for cleaning in a washing machine. When cleaning the fabric, it is important to observe the following: Always use a natural soap. Never detergent. Water should be cold to lukewarm. Never more than 100 degrees. Air dry only. Never apply heat to the fabric. HARDWARE MAINTENANCE Replace any parts that become damaged. Periodically check all mounting hardware, screws, lags, etc., and re-tighten when necessary. Periodically flush the arm assemblies with low pressure water to keep them clean and free of debris. NOTE: Avoid introducing water into the motorized and non-motorized housings. MOTOR MAINTENANCE Check all wiring and connections for wear. Repair when needed. Carefree of Colorado Figure 13. Control Switch. Check that the sealant is providing a good seal and no water is accumulating on the wiring. T0001 10 052504-001
TROUBLESHOOTING Use the following table to help troubleshoot the system. CAUTION TO PREVENT PERSONAL INJURY OR DAMAGE THAT MAY NOT BE COVERED BY WARRANTY, REPAIRS AND ADJUSTMENTS TO THE AWNING SPRINGS SHOULD BE MADE BY FACTORY AUTHORIZED PERSONNEL ONLY. CALL THE CUSTOMER SERVICE DEPARTMENT FOR THE NEAREST AUTHORIZED DEALER. Troubleshooting Guide Symptom Problem Solution MOTOR System does not respond. AWNING ASSEMBLY Awning pulls away from side of vehicle. Power supply may be off. Control switch wired incorrectly. Vehicle battery needs charging The motor s thermal protective device has shut the motor off. Awning not installed properly/incorrect installation on surface. Awning is not mounted in awning rail correctly. Check power supply and cables. Review the wiring diagram. Recharge the battery. Wait 15 minutes for cool down. Review the section Installing the Awning Rail. For further questions, contact Carefree or your installation technician. Verify that the awning assembly is securely attached to the rail. See Installing the Awning Assembly for more information. 11 052504-001
WARRANTY POLICY 1. DURATION: Two years on parts, freight and labor on canopies; and four years parts, freight and labor on spring assemblies (or motors), rollers and hardware. Please retain dated proof of purchase (receipt). Warranty duration is not extended by the length of time the product is not in use or the time which purchaser is deprived the use of the product. The duration of coverage on parts and repairs provided as per this warranty shall be determined by the date of the original product purchase (not by the date of repairs). 2. PRODUCTS:. Warranty covers all Carefree of Colorado ONE- Touch, Spirit, Fiesta, Simplicity, patio awnings and all Carefree Window Awnings installed and operated as per Warrantor s instructions. 3. WHO GIVES THIS WARRANTY (WARRANTOR); Carefree of Colorado a Scott Fetzer Company 2145 West 6th Avenue Broomfield, CO 80020 Phone: 1-303-469-1152 Fax: 1-303-460-9106 No other person or company is authorized to change or amend the Warrantor s obligations set forth in this warranty. 4. WHO RECEIVES THIS WARRANTY (ORIGINAL PURCHASER): The first ( Original Purchaser ), other than for purposes of resale, of the Carefree of Colorado product that is properly installed and operated within the continental US and Canada. 5. WHAT IS COVERED UNDER THIS WARRANTY: Defects on the manufacturer s material and workmanship of product under normal use, and which occur within the duration of the warranty period. On all awnings, the following parts are covered only as follows: a.) Fabrics, free from quality defects (normal wear and fading are excluded); b.) Roller Tube, against extrusion defects; c.) Springs (or Motor) Assembly(ies), against breakage; and d.) Hardware, against extrusion defects. 6. WHAT IS NOT COVERED UNDER THIS WARRANTY: A) Fabric damage such as pinholes or tears not reported within ten (10) calendar days of purchase; B) Improper installation and/or any damage or failure that results from improper installation of the product, including fabric damage caused by improper installation; C) Product abuse and normal wear. D) Conditions that are not related to the material or workmanship of the product: including any failure that results from an accident, wind, rain, water pooling, or other acts of God; purchaser s abuse; neglect; failure to operate, or use or maintain the product in accordance with the instructions provided in the Owner s Manual supplied with the product; (failure to operate the product(s) in accordance with instructions in the Owner s Manual and on the product shall also include the removal or alteration of any product component or device. In the event of any such removal or alteration, this warranty is void); E) ANY INCIDENTAL, INDIRECT, OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY DEFECT, FAILURE, OR MALFUNCTION OF THE CAREFREE OF COLORADO PRODUCT. Some states do not allow the exclusion or limitation on incidental or consequential damages, so the above limitation or exclusion may not apply to you. F) Any failure that results from the use of another product with a Warrantor s product that is not specifically approved by the Warrantor. 7. RESPONSIBILITIES OF WARRANTOR UNDER THIS WARRANTY: Repair or replace at Warrantor s option, of the covered part(s) which Warrantor, in the exercise of its reasonable discretion, determines to be defective; provided that the Warrantor receives notice of the defect within the stated warranty period for that respective product/component. Warrantor will also pay the respective servicing dealer or agent for performing any repairs authorized by Warrantor as per the terms of this warranty. 8. RESPONSIBILITIES OF ORIGINAL PURCHASER UNDER THIS WARRANTY: A) Retain dated Proof of Purchase for specific product, and provide it as requested. B) Inspect the awning upon purchase to confirm the condition of the canopy and the proper operation of the product. C) Perform Periodic Preventative Maintenance as specified in Owners Manual. D) Deliver any product claimed or found defective during warranty period to the nearest Carefree of Colorado Authorized Service Dealer. The Original Purchaser is responsible for any expenses related to delivery or pick up of product to/from the Service Dealer. Visit carefreeofcolorado.com for the name of nearest Authorized Service Dealer, or call Carefree at the phone number shown in section five. E) Use reasonable care in the operation and maintenance of the products as described in section four of this manual. 9. WHEN WARRANTOR WILL PERFORM REPAIR OR REPLACEMENT UNDER WARRANTY. A) Repair or replacement will be scheduled and performed according to normal work flow at the nearest Authorized Service Dealer, and depending on the availability of replacement parts. B) If the purchaser does not receive satisfactory results from the Authorized Service Dealer, the purchaser should contact the Carefree of Colorado Customer Service Department (see paragraph 2). THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. No action to enforce this warranty shall be commenced later than 30 days expiration of the warranty period. The Duration of this Limited Warranty also limits the duration of any implied warranty such as warranty of merchantability or fitness for a particular use or purpose. Some states do not allow such limitations so the implied warranty limitation may not apply to you. Carefree of Colorado reserves the right to change the specifications and design of any product without notice and with no obligation to make corresponding changes to products previously manufactured. 12 052504-001
CAREFREE WARRANTY REGISTRATION CARD YOU MUST FILL THIS CARD OUT AND SEND IT TO CAREFREE WITH A COPY OF YOUR INVOICE TO VALIDATE YOUR WARRANTY! Please Print Clearly: Dealer/Installer Name Your Name Your Address E-Mail Phone Purchase Date Product Part Number Product Serial Number Please rate your satisfaction of the following: 1 = not satisfied 5 = very satisfied Installation Professionalism of Installer Did anyone refer you to Carefree? Name of Person Product Operation Product Quality NOTE: We pay for referrals. Please call if you know of someone interested in our products. 1-800-621-2617 Suggestions/Comments: Description of Product (Patio Awning, etc.) I have inspected the product and find it free from visible defects and in apparent good working order. I understand that Carefree of Colorado will not be responsible for any damage or expenses caused by improper installation which shall be the sole responsibility of the installing party. Further, I understand that the dealer can make no representation regarding the merchantability of specific attributes of this product other than those set forth in the limited warranty. I also understand that in order form my warranty to be valid, I must mail in this card and keep my original invoice as proof of purchase. Customer Signature 1. Fill Out Registration, 2. Fold on the Dotted Line, 3. Tape Closed, 4. Apply Postage and Mail! Thanks for choosing Carefree Date
Return Address: Carefree of Colorado A Scott Fetzer Company 2145 W. 6 th Avenue Broomfield, CO 80020 Place Stamp Here
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